SPIE Press – Optical System Design ISBN # 0-07-134916-2 This chapter is an excerpt from Optical System Design by Robert E. Fischer and Biljana Tadic-Galeb, published by SPIE Press and McGraw-Hill. There are several software programs that are available to help design an optical system. But the software can’t give the designer all of the practical considerations with regard to making the lenses. “Optical Manufacturing Considerations” addresses the most common manufacturing issues that push out delivery or drive up cost. A little effort to deal with these issues at the design phase will save time and money. Bob Wiederhold and I were grateful for the opportunity to contribute our manufacturing expertise to this ‘down to earth’ text about optical design. It is now out as a 2nd Edition with additional technical information and examples. This book is a useful desk reference for everyone involved with optical systems. We hope that this chapter is informative and helpful. Please send us your comments at [email protected]. Thank you. Best of luck with your project, Rick Plympton CEO/VP Sales Optimax Systems, Inc. 6367 Dean Parkway Ontario, NY 14519 Tel: 585 265 1066 Fax: 585 265 1033 e-mail: [email protected] 17-1 SPIE Press – Optical System Design ISBN # 0-07-134916-2 Chapter 17 Optical Design Considerations for Optics Fabrication From the point of view of a lens manufacturer, what design attributes have the most influence on manufacturing efficiency? The primary design considerations are optical material, component size, shape, and manufacturing tolerances. All of these attributes are variable at the design phase and can have significant impact on lens manufacturing costs. In order to narrow the scope of this chapter, the text assumes the manufacture of a precision glass lens of approximately 50mm diameter using grinding and polishing techniques. The information is presented in the following order: 1. Material — a summary of manufacturing considerations for optical glasses 2. Manufacturing — an overview of conventional and advanced process technologies 3. Special Fabrication Considerations — a review of tolerancing trade-offs and finishing options 4. Relative Manufacturing Cost — an analysis of manufacturing variables 5. Sourcing Considerations — suggestions for achieving project goals 6. Conclusion — summary table for quick reference. While this analysis is based on a 50mm diameter glass lens, it can also be adapted to include specific market niches such as micro-optics (diameters smaller than 5mm), macro-optics (diameters larger than 300mm), prisms and flats, molded glass and plastic optics, diamond turned crystal and metal optics, and diffractive optical elements. These niches are addressed in additional chapters of this book. 17-2 SPIE Press – Optical System Design ISBN # 0-07-134916-2 17.1 Material There are more than 100 different optical glasses available worldwide, and each has a unique set of optical, chemical, and thermal characteristics. Only a few glass manufacturers in the world produce these optical glasses, and each manufacturer has a company-specific glass naming convention. Cross-referencing the glasses is possible via a six-digit glass code (ABCXYZ) that is derived from the index of refraction (nd = 1.ABC) and the Abbe value (νd = XY.Z). For the vast majority of optical applications, glasses from differing manufacturers can be direct substitutes. Lens designers should be aware, however, that equivalent glasses having the same six-digit glass code might not have exactly the same optical, chemical, and mechanical properties. For example, Schott’s SK-16 (620603) has slightly different characteristics than Ohara’s S-BSM-16 (620603). Be aware: optical design software will define glasses that can achieve a desired optical performance, but it cannot determine the glasses’ current availability in the market. Nor will the software give consideration for the glasses’ chemical and thermal properties. For example, it may be important to consider that the index of refraction of a glass changes with temperature at a known rate. Other parameters that are important to consider are spectral transmission, dispersion, material quality, mechanical, chemical, and thermal properties. Design Considerations Material quality is defined by tolerances of optical properties, striae grades, homogeneity, and birefringence. Optical properties include spectral transmission, index of refraction, and dispersion. Data for each glass type is available from its manufacturer. If tighter than standard optical properties are required, then additional cost and time are usually associated with obtaining the material. Specification of glass based on material quality is provided in the 17-3 SPIE Press – Optical System Design ISBN # 0-07-134916-2 International Standard ISO 10110 and the U.S. military specification MIL-G-174B. A brief summary of glass material specifications using nomenclature from Schott Optical Glass is shown in Figure #1. Before finalizing an optical design, some consideration should be given to glass cost and availability. Glass prices vary from a few dollars per pound to several hundred dollars per pound. In some cases, it may be more economical to add a lens to the design in order to avoid expensive glasses. In addition, many glasses are not regularly stocked. Instead they are melted to order, which can take several months. Pricing and melt frequencies are available from glass manufacturers. Each manufacturer has a list of “Preferred” glasses that are most frequently melted and usually available from stock. It’s important to note that “Preferred” does not imply “best glass type available.” From a manufacturing perspective, “Preferred” refers only to the availability of the glass in stock. For example, BK-7 is readily available from stock and is among the most economical of glass types. On the other hand, a glass like SF-59 is not made as frequently and may not be as readily available. If delivery is a concern, the designer may want to use only glasses from the frequently melted glass list. Striae Grade AA (P) is classified as “precision striae” and has no visible striae. Grade A only has striae that are light and scattered when viewed in the direction of maximum visibility. Grade B has only striae that are light when viewed in direction of maximum visibility and parallel to the face of the plate. Birefringence is the amount of residual stress in the glass and depends on annealing conditions, type of glass, and dimensions. The birefringence is stated as nm/cm difference in optical path measured at a distance from the edge equaling 5% of the diameter or width of the blank. Normal quality is defined as (except for diameters larger than 600mm and thicker than 100mm): i. Standard is less than or equal to 10 nm/cm ii. Special Annealing (NSK) or Precision Annealing is less than or equal to 6 nm/cm iii. Special Annealing (NSSK) or Precision Quality after Special Annealing (PSSK) is less than or equal to 4 nm/cm. Homogeneity is the degree to which refractive index varies within a piece of glass. The smaller the variation, the better the homogeneity. Each block of glass is tested for homogeneity grade. Normal Grade ±1 x 10-4 H1 Grade ±2 x 10-5 H2 Grade ±5 x 10-6 H3 Grade ±2 x 10-6 H4 Grade ±1 x 10-6 17-4 SPIE Press – Optical System Design ISBN # 0-07-134916-2 Tolerances of Optical Properties consist of deviations of refractive index for a melt from values stated in the catalog. Normal tolerance is ±0.001 for most glass types. Glasses with nd greater than 1.83 may vary by as much as ±0.002 from catalog values. Tolerances for nd are ±0.0002 for Grade 1, ±0.0003 for Grade 2 and ±0.0005 for Grade 3. The dispersion of a melt may vary from catalog values by ±0.8%. Tolerances for vd are ±0.2% for Grade 1, ±0.3% for Grade 2 and ±0.5% for Grade 3. <<Figure #1: Glass Material Specifications >> Fabrication Considerations Because the mechanical, chemical, and thermal properties of glass are what determine the ease or difficulty of making optics from the material, these properties are of particular interest to the optical fabricator. Mechanical properties include hardness and abrasion resistance. These properties determine the rate at which material is removed, and should be among the first to consider. Hardness is measured in accordance with ISO 9385. It is measured with a micro- hardness tester that utilizes a precision diamond point applied with a specific amount of force. This probe contacts and penetrates the polished glass sample at room temperature. Carefully measuring the resultant indentation yields a calculation known as the “Knoop hardness” of the material. Knoop hardness ranges from 300 to 700 for most optical glasses, where 300 represents a soft glass and 700 harder glasses. In general, the harder the glass the longer the time required to grind and polish the lens. Abrasion resistance affects how fast the glass will process. Abrasion resistance is the ratio of material removed on a test piece of glass to the material removed from a BK-7 sample. The abrasion resistance of BK-7 is set to equal 100. The higher the number, the faster material will be removed. The values range from about 60 to 400. Compared to BK-7, a glass with a value of 60 will take almost twice as long to process. Conversely, glass with a value of 400 will take only one-quarter the time. The process time seems to imply that softer glasses are cheaper to fabricate. One must remember, however, that other factors such as cosmetic finish may offset 17-5 SPIE Press – Optical System Design ISBN # 0-07-134916-2 potential savings. Soft glasses are more difficult to polish to achieve very good cosmetics and low RMS surface roughness.